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Analysis of exhaust waste heat recovery from a dual fuel low temperature
combustion engine using an Organic Rankine Cycle
Kalyan K. Srinivasan, Pedro J. Mago, Sundar R. Krishnan*
Department of Mechanical Engineering, Mail Stop 9552, 210 Carpenter Building, Mississippi State University, Mississippi State, MS 39762, USA
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 9 November 2009
Received in revised form
9 February 2010
Accepted 10 February 2010
Available online 8 April 2010
This paper examines the exhaust waste heat recovery potential of a high-efciency, low-emissions dual
fuel low temperature combustion engine using an Organic Rankine Cycle (ORC). Potential improvements
in fuel conversion efciency (FCE) and specic emissions (NOx and CO2) with hot exhaust gas recirculation (EGR) and ORC turbocompounding were quantied over a range of injection timings and engine
loads. With hot EGR and ORC turbocompounding, FCE improved by an average of 7 percentage points for
all injection timings and loads while NOx and CO2 emissions recorded an 18 percent (average) decrease.
From pinch-point analysis of the ORC evaporator, ORC heat exchanger effectiveness (3), percent EGR, and
exhaust manifold pressure were identied as important design parameters. Higher pinch point
temperature differences (PPTD) uniformly yielded greater exergy destruction in the ORC evaporator,
irrespective of engine operating conditions. Increasing percent EGR yielded higher FCEs and stable
engine operation but also increased exergy destruction in the ORC evaporator. It was observed that hot
EGR can prevent water condensation in the ORC evaporator, thereby reducing corrosion potential in the
exhaust piping. Higher 3 values yielded lower PPTD and higher exergy efciencies while lower 3 values
decreased post-evaporator exhaust temperatures below water condensation temperatures and reduced
exergy efciencies.
2010 Elsevier Ltd. All rights reserved.
Keywords:
Waste heat recovery
Organic Rankine Cycle
Dual fuel engines
Low temperature combustion
1. Introduction
National energy security, rising energy prices, increasingly
competitive global markets, and stringent environmental
emissions regulations are primary driving forces in the search for
sustainable and economically viable technologies for efcient and
clean approaches to energy conversion and utilization. Internal
combustion engines (IC) are prime movers of choice when high
power densities and efciencies are desirable. Due to relatively
cheap fuel availability in past decades, IC engines had been
optimized for high power densities and low-emissions. However, in
recent years, with escalating fuel prices and sustainability concerns,
engine efciency has assumed greater importance.
Over the past 150 years since the invention of the IC engine
great strides have been made in improving its fuel conversion
efciency and reducing its emissions. As a testament to this fact, the
average peak brake thermal efciency of on-road spark ignition
power trains is about 30% while that of on-road compression
ignition power trains is about 41% [1]. Further improvements in fuel
* Corresponding author. Tel.: 1 662 325 1544; fax: 1 662 325 7223.
E-mail address: krishnan@me.msstate.edu (S.R. Krishnan).
0360-5442/$ e see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2010.02.018
2388
Nomenclature
ALPING
LTC
BTDC
WHR
ORC
CCHP
PPTD
COV
EGR
BMEP
IC
P
T
H
DH
h
E_
h
Cp
R
Q_
_
m
_
W
FCE
LHV
BSNOx
BSCO2
NOx
CO2
CO
HC
PM
EPA
ppm
power (kW)
Fuel Conversion Efciency (%)
Lower Heating Value (kJ/kg)
Brake Specic Nitrogen Oxide emissions (g/kWh)
Brake Specic Carbon Dioxide emissions (g/kWh)
oxides of nitrogen emissions
Carbon dioxide emissions
carbon monoxide emissions
hydrocarbon emissions
Particulate Matter
Environmental Protection Agency
parts per million
Subscripts:
1, 2, 20 thermodynamic states of exhaust gas
3e6
thermodynamic states of Organic Rankine Cycle uid
in
intake
exh
exhaust
TT
turbocharger turbine
s
isentropic end state
t
ORC turbine
p
ORC pump
max
maximum
orc
Organic Rankine Cycle
eng
engine
ng
natural gas
eng-orc engine-ORC turbocompounded system
2389
Table 1
Selective Review of research on WHR technologies using Rankine bottoming cycles A: Analytical, S: Simulation, T: Theoretical, E: Experimental, R: Review.
Ref.
Nature
of study
Method
Salient conclusions
[6]
[8]
[9]
[11]
A/E
[12]
Transient 10/15 mode Japanese drive cycle simulations indicate that the
WHR conguration using the novel steam expander is effective even at
low speed urban driving conditions. Predicted an average overall
improvement of 6.1% in thermal efciency over the simulated 10/15
mode drive cycles
[13]
E/A
Simulations revealed that water would be the ideal uid for WHR for
conguration A; however, an organic solvent such as ethanol would be
ideal for conguration B. Experiments revealed that 0.7e2 kW of extra
power could be produced from WHR. This corresponded to a 10%
improvement in engine power under transient conditions.
[15]
[17]
[19]
S/T
[20]
popular choice due to their low setup and operational costs and
relative ease of operation and maintenance [27]. Therefore,
investigation of technologies such as WHR that can signicantly
improve the overall efciency of IC engine powered CCHP systems
is of paramount interest.
1.4. Objectives
The specic objectives of this paper are,
2390
Fig. 1. Schematic representation of (a) isentropic, (b) wet and (c) dry uids.
Specication
Engine type
Bore (mm)
Stroke (mm)
Compression ratio
Combustion system
Diesel injection system
Diesel injector
Natural gas fueling
Engine speed, rev/min
Brake power, kW (engine load)
BMEP, bar (engine load)
Intake pressure, kPa (engine load)
Intake temperature, C (engine load)
1-cylinder, 4-stroke
137
165
14.5:1
Direct injection, Mexican hat
Electronic, common-rail
Pencil-type, four-holes
Manifold fumigation
1700
21 (half), 10.5 (quarter)
6 (half), 3 (quarter)
181 (half), 151 (quarter)
75 (half), 115 (quarter)
2391
2392
T20 T2 hTT T2 T20 s
(1)
T20 s T2
P2
P2'
!1g g
(2)
The ratio of specic heats (g) of the exhaust gas was assumed to
be 1.37 (for air at an average temperature of 400 C) for these
calculations.
5. Organic Rankine Cycle analysis
This section presents the equations used to estimate the
exhaust WHR potential using ORC turbocompounding from
actual engine data. Measured exhaust parameters such as
temperatures, pressures and ow rates, at quarter load (10.5 kW)
and half load (21 kW) from the ALPING LTC engine (see
Experimental Setup section) have been used as inputs for the
_ exh Cpexh T20 T5
Q_ max m
(3)
_ exh is
where Cpexh is the constant specic heat of the exhaust gases, m
the mass ow rate of the exhaust, T5 is the temperature of the
organic working uid entering the evaporator, and T20 is the
temperature of the exhaust gases leaving the engine and entering
the evaporator.
The actual energy that can be used in the evaporator as well as
the temperature of the exhaust leaving the evaporator (T3) can be
estimated using the heat exchanger effectiveness as follows:
_ exh cpexh T20 T3
Q_ actual 3Q_ max m
where, 3 is the heat exchanger effectiveness.
Fig. 3. Schematic of Engine-ORC conguration showing a typical data set for quarter load engine operation, 50 BTDC injection timing, and 0% EGR.
(4)
Table 3
Values used to simulate the ORC.
Turbine Efciency (%)
Pump Efciency (%)
Quality of organic uid leaving evaporator
Evaporator Pressure (MPa)
Condenser Temperature (K)
82
80
1
2
303
FCEeng
_ eng
W
_
_ ng LHVng
mdiesel LHVdiesel m
FCEengorc
The mass ow rate of the organic working uid and the net
power output from the ORC can be estimated as:
_ orc
m
Q_ actual
Q_ actual
qevap
h6 h5
_ t W
_ p
_ orc W
W
(5)
(6)
_ t hW
_
_ orc h6 h7s m
_ orc h6 h7
W
t
t; ideal ht m
(7)
_
_ orc h4 h5s
_ p W p; ideal m
_ orc h4 h5
W
m
(8)
hp
hp
2393
_
_
where W
t; ideal and W p; ideal are the ideal power of the turbine and
pump, respectively, ht and hp are the isentropic efciencies of the
turbine and pump, h6 and h7s are the enthalpies of the working
uid at the inlet and outlet of the turbine for the ideal case, and h4
and h5s are the enthalpies of the working uid at the inlet and
outlet of the pump for the ideal case. The ORC parameters used in
this analysis are specied in Table 3.
_ eng W
_ orc
W
_
_ ng LHVng
mdiesel LHVdiesel m
(9)
(10)
T 0 T3
DH550 DH56 T20
Tpinch b DH550 DH56 T20 2
DH56
(11)
Fig. 4. Schematic of TeDH diagram (not-to-scale) used for the pinch-point analysis in the evaporator, showing a typical data set for quarter load engine operation, 50 BTDC
injection timing, and 0% EGR; Note: DH is the product of the specic enthalpy of the ORC working uid at a given state and its mass ow rate.
2394
(12)
E_
E_ E_
(13)
where E_ useful and E_ available are the actual exergy used and the
theoretically available exergy at the evaporator, E_ 5 and E_ 6 are the
exergy ow rates of the organic working uid entering and leaving
the evaporator, respectively, and E_ 2 and E_ 3 are the exergy ow rates
of the exhaust gases entering and leaving the evaporator,
respectively.
The exergy ow rate of the organic working uid at any point of
the ORC can be determined as:
_ orc hi ho To si so
E_ i m
(14)
T
P
_ exh cpexh Tj To cpexh ln j Rexh ln j
E_ j m
To
Po
(15)
cpexh
gR
; g 1:37; Rexh zRair 0:287 kJ=kg:K
g1
(16)
EGRratio
_
CO2 EGR m
z EGR
_ int
CO2 exh m
(17)
where, CO2 EGR and CO2 exh are CO2 concentrations in the intake
_ int is the total mass ow rate
and exhaust manifolds, respectively, m
_ EGR is the mass ow
(of air and EGR) in the intake manifold, and m
Fig. 5. Variation of the engine (E) and combined engine-ORC (E-ORC) fuel conversion
efciency with the injection timing for different EGR for quarter load operation
(Power 10.5 kW, ORC evaporator effectiveness, 3 0.7).
2395
Fig. 6. Variation of the engine and combine engine-ORC fuel conversion efciency
with the injection timing for different EGR for half load operation (Power 21 kW,
ORC evaporator effectiveness, 3 0.7).
As shown in Fig. 6, for half load operation (21 kW) the maximum
amount of EGR was limited to 8%. Higher amounts of EGR led to
engine knock and unstable engine operation. At the representative
injection timings of 20 BTDC and 60 BTDC, addition of EGR (8%
EGR) results in FCE increasing from baseline values of 26 percent
and 30 percent, respectively, to 27 percent and 35 percent,
respectively. Moreover, with the addition of EGR, as observed for
the quarter load case, the range of injection timings for stable
engine operation was extended from 20 BTDC e 60 BTDC to 20
BTDC e 75 BTDC. Exhaust waste heat recovery using ORC turbocompounding led to further improvements in FCE values: from 26
percent to 32 percent at 20 BTDC and from 30 percent to 40
percent at 60 BTDC. Overall, the results show that exhaust waste
heat recovery using ORC turbocompounding seems to be more
benecial for quarter load operation in comparison to half load
operation. This is attributable to the lower exhaust gas temperatures in the quarter load case, which led to higher exergy efciencies in the ORC evaporator.
Fig. 7. Variation of the PPTD with the injection timing for different EGR for quarter
load and half load operation (3 0.7).
Fig. 8. Variation of the evaporator exergy efciency with the PPTD for different
injection timings and EGR for quarter load operation and half load operation (3 0.7).
2396
Fig. 9. Variation of the exhaust gases temperature after the evaporator with the
injection timing for different EGR for quarter load operation and half load operation
(3 0.7).
Fig. 10. Variation of the evaporator exergy efciency with the PPTD for 22% EGR for
quarter load operation for different evaporator effectiveness (3).
Fig. 11. Variation of the evaporator exergy efciency with the PPTD for 22% EGR for
quarter load operation for different evaporator effectiveness (3).
Engine (E)
Engine-ORC (E-ORC)
W
(kW)
NOx
(g/kWh)
CO2
(g/kWh)
W
(kW)
NOx
(g/kWh)
CO2
(g/kWh)
EGR 0%
20
30
40
50
55
10.47
10.64
10.68
10.59
10.53
0.65
2.13
1.59
0.21
0.08
568.10
536.77
531.63
536.63
554.61
12.73
12.72
12.69
12.60
12.64
0.53
1.75
1.31
0.18
0.07
467.59
441.80
437.57
441.69
456.49
EGR 11%
20
30
40
50
55
60
65
70
10.78
10.71
10.49
10.61
10.68
10.74
10.64
10.70
0.33
1.53
2.50
1.09
0.30
0.08
0.07
0.05
642.52
576.74
575.51
576.55
581.63
588.65
601.80
622.22
13.12
12.73
12.42
12.52
12.59
12.74
12.70
12.86
0.27
1.26
2.06
0.90
0.25
0.06
0.05
0.04
528.85
474.70
473.69
474.55
478.73
484.51
495.33
512.14
EGR 21%
20
30
40
50
55
60
65
70
10.55
10.64
10.46
10.46
10.58
10.63
10.54
10.73
0.18
0.81
1.87
0.88
0.41
0.09
0.05
0.04
646.40
581.12
593.70
589.86
585.39
588.27
595.03
598.48
12.56
12.34
12.06
12.06
12.19
12.28
12.23
12.48
0.15
0.67
1.54
0.72
0.34
0.08
0.04
0.03
532.04
478.31
488.66
485.51
481.83
484.20
489.76
492.60
2397
quarter load are equally valid for half load operation; therefore,
only quarter load trends will be discussed. With the addition of
EGR, both specic NOx and CO2 emissions were observed to
increase. Addition of hot EGR led to higher intake temperatures,
and consequently, the combustion temperatures were higher,
resulting in increased NOx emissions. However, higher CO2 emissions with increasing EGR reect better fuel conversion efciencies.
In other words, EGR addition favors faster combustion rates,
thereby burning the fuel (in this case natural gas and very small
diesel quantities) more completely and leading to higher CO2
emissions. In general, total engine power output registered an
average increase of 20 percent with ORC turbocompounding (EORC). Similarly, both specic NOx and specic CO2 emissions were
observed to decrease by 18 percent on an average with E-ORC. It is
important to note that without any expensive aftertreatment
technologies, it is possible to achieve a signicant reduction in
engine-out brake specic emissions by employing exhaust waste
heat recovery techniques such as ORC turbocompounding. This is
a consequence of accounting for total (engine plus ORC) power
output in the calculation of brake specic emissions as explained
below.
BSNOx eng-orc
_ NOx
m
_ eng
W
(18)
BSCO2 eng-orc
_ CO2
m
_ eng
W
(19)
BSNOx eng-orc
_ NOx
m
_
_ orc
W eng W
(20)
BSCO2 eng-orc
_ CO2
m
_ eng W
_ orc
W
(21)
Table 5
Half Load e Specic Emissions.
Injection
Timing
Engine (E)
Engine-ORC (E-ORC)
W
(kW)
NOx
(g/kWh)
CO2
(g/kWh)
W
(kW)
NOx
(g/kWh)
CO2
(g/kWh)
EGR 0%
20
30
40
50
55
60
65
21.13
21.02
21.07
21.03
21.07
21.09
21.01
0.65
1.61
1.75
0.36
0.10
0.04
0.03
461.90
437.77
441.05
442.24
443.24
444.45
453.23
24.97
24.49
24.42
24.33
24.38
24.50
24.54
0.53
1.32
1.44
0.29
0.08
0.03
0.02
380.19
360.32
363.02
364.00
364.83
365.82
373.05
EGR 5%
20
30
40
50
55
60
65
70
20.84
20.82
20.73
20.77
21.08
21.00
20.96
20.70
0.53
1.68
1.94
0.56
0.22
0.05
0.03
0.03
495.93
466.94
472.68
467.98
467.27
464.74
475.20
483.70
24.70
24.29
24.05
24.07
24.39
24.31
24.39
24.30
0.43
1.39
1.59
0.46
0.18
0.04
0.02
0.02
408.19
384.33
389.05
385.19
384.60
382.52
391.13
398.12
EGR 8%
20
30
40
50
55
60
65
70
75
21.20
21.17
21.00
20.74
20.96
20.89
20.95
20.82
20.96
0.29
1.08
1.89
0.98
0.35
0.17
0.05
0.03
0.03
536.10
478.02
479.13
480.40
475.47
478.26
480.26
484.08
491.00
25.35
24.61
24.17
23.83
24.08
24.00
24.09
23.99
23.99
0.23
0.89
1.56
0.81
0.28
0.09
0.04
0.02
0.02
441.26
393.45
394.36
395.41
391.35
393.65
395.29
398.44
404.14
As seen in Eqs. (20) and (21), the total brake power, which is
the denominator of Eqs. (18) and (19) increases with ORC
turbocompounding, whereas the numerator remains the same.
Therefore, the brake specic emissions are reduced without any
FCE penalty or other changes in the combustion process. Further, it
is to be noted that the lowest specic NOx emissions at quarter load
operation of 0.03 g/kWh and 0.02 g/kWh at half load operation are
well below the US EPA NOx emissions standards for off-highway
heavy duty diesel engines. Clearly, exhaust waste heat recovery in
addition to the novel ALPING LTC strategy discussed in this study
help achieve very low NOx emissions while maintaining high
thermal efciencies. Moreover, the reduction in specic CO2
emissions with exhaust waste heat recovery using ORC turbocompounding indicates its potential for reducing greenhouse gas
emissions.
8. Conclusions
In this paper, the exhaust waste heat recovery potential from
the novel low temperature, low-emissions and high-efciency
Advanced Low Pilot Ignited Natural Gas (ALPING) low temperature combustion (LTC) using a bottoming Organic Rankine Cycle
(ORC) was examined. The potential improvements in fuel
conversion efciency (FCE) and brake specic emissions (NOx
and CO2) with hot EGR addition and waste heat recovery (WHR)
using ORC turbocompounding were quantied. In addition, the
nature of irreversibilities in the ORC bottoming cycle was
analyzed from a second law perspective and the basic design
2398
criteria for the ORC evaporator were established using a pinchpoint analysis. The following conclusions can be drawn from
the analyses:
1. With hot EGR addition, FCE improved for all injection timings at
half and quarter loads, and ORC turbocompounding along with
hot EGR led to even higher efciencies. For example, at 60 BTDC
injection timing and quarter load, FCE increased from the baseline (0% EGR) value of 20 percent to 28 percent with 22% EGR
alone, and eventually to 32 percent with 22% EGR and ORC
turbocompounding. Half load FCE improvements at 60 BTDC
injection timing were more modest (from 30 percent at 0% EGR
to 40 percent at 8% EGR and ORC turbocompounding) and
therefore exhaust WHR with ORC turbocompounding appears
more benecial at quarter load.
2. Engine-out specic emissions of NOx and CO2 can be decreased
substantially by adopting ORC turbocompounding without any
FCE penalty, combustion modications, or the need for expensive aftertreatment devices. With ORC turbocompounding, both
NOx and CO2 emissions were reduced by about 18 percent (on an
average).
3. For all injection timings, the pinch-point temperature difference
(PPTD) between exhaust gas in the ORC evaporator and the
saturation temperature of the organic uid (R113) increased
with increasing EGR, indicating a greater potential for heat
transfer. However, irrespective of engine load, injection timing,
or percent EGR, higher PPTD values uniformly led to lower
exergy efciencies of the ORC evaporator, signifying greater
exergy destruction.
4. With increasing hot EGR, exergy destruction in the ORC
evaporator increased. However, EGR facilitated more stable
engine operation, higher FCEs, and lower emissions. Further,
the addition of hot EGR ensured that post-evaporator exhaust
temperatures were above the condensation line, i.e., hot EGR
will prevent water condensation in the ORC evaporator tubing,
thus reducing the potential for corrosion in the exhaust
manifold.
5. The heat exchanger effectiveness (3) of the ORC evaporator was
identied as an important design parameter. In general, higher 3
values (3 0.8) yielded the lowest PPTD and highest exergy
efciencies while lower 3 values (3 0.6) decreased postevaporator exhaust temperatures below water condensation
temperatures (at a given exhaust manifold pressure) and
reduced exergy efciencies. However, resorting to higher 3
values may increase heat exchanger costs. Consequently, the
ORC heat exchanger effectiveness, exhaust manifold pressures,
and percent EGR must be chosen carefully to ensure the best
tradeoffs between exergy efciency of the ORC, incremental
system cost, system reliability, exhaust emissions, and overall
fuel conversion efciencies.
Acknowledgments
The authors gratefully acknowledge the nancial support
provided by the Micro-CHP and Biofuel Center and the Sustainable
Energy Research Center (SERC) of Mississippi State University.
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